Molding and Casting

Molding and casting are fundamental processes in manufacturing, art, and various other industries, allowing the replication of objects with precision and efficiency.

Group Assignment

The Kannai team as usual was divided into two and i worked with Ahmad Tijjani Ishaq The task is to review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them compare printing vs milling molds Our group assignment page

Individual Assignment

All source files can be found Here at the side bar.

Assignment for the week is to design a mold around the process you’ll be using, produce it with a smooth surface finish, and use it to cast parts extra credit: use more then two mold parts

Molding involves creating a negative impression or mold of an object, which is then used to produce multiple replicas. There are several types of molds, each suited to different materials and requirements:

Solid Molding: This involves creating a solid mold around the object using materials like silicone rubber or plaster. The object is placed inside the mold, and once the material has set, the original object is removed, leaving behind a negative space.
Flexible Molding: Silicone rubber is often used for flexible molds, allowing for easy removal of intricate objects. These molds can capture fine details and are often used in the reproduction of sculptures, figurines, and prototypes.
Rigid Molding: Materials like plaster, fiberglass, or even metal can be used for rigid molds, providing stability and durability. Rigid molds are suitable for objects with simpler shapes or when large quantities of replicas are needed.
Two-Part Molding: This technique involves creating a mold in two or more parts to capture complex shapes or objects with undercuts. Each part of the mold is created separately, and then they are assembled around the original object to form a complete mold.

Casting is the process of pouring a liquid or semi-liquid material into a mold to create a solid object. Common casting materials include:

Resins: Polyurethane, epoxy, and polyester resins are popular choices for casting due to their ease of use, low cost, and wide range of applications. They can be mixed with additives to achieve different properties like flexibility, transparency, or strength.
Metals: Metals like aluminum, bronze, and pewter can be melted and poured into molds to create metal castings. This process is commonly used in the production of jewelry, sculptures, and mechanical parts.
Plaster: Plaster is a versatile casting material that is easy to work with and relatively inexpensive. It is often used for making prototypes, architectural models, and decorative objects.
Concrete and Cement: These materials are used for casting larger objects like statues, furniture, and architectural elements. They can be reinforced with fibers or additives to improve strength and durability.

After the casting material has been poured into the mold, it is allowed to cure or harden. Once set, the mold is removed, revealing the cast object. Depending on the complexity of the object and the material used, additional finishing steps such as sanding, painting, or polishing may be required to achieve the desired final result.

Molding and casting offer a versatile and cost-effective way to produce multiple copies of an object, whether it's for artistic, industrial, or commercial purposes. With advancements in materials and technologies, these processes continue to evolve, enabling creativity and innovation in various fields.

To complete my assignment i follow the following steps.

I first did a 3D design of my possitive mold using fusion 360. My design is a bangle with a heart at the center dedicated to my fiance.

Then i exported the stl file
Next i used the mods site. i chose program, gcode, mill 2.5D stl which is used for the rough cut.
Then i generated the 2.5d gcode and repeated same process for mill 3D stl for the finish cut

With my gcode's ready i proceed to cut my mold using the Genmitsu milling CNC. I use the following:
- Material -- machinable Wax
- Toolbit-- 1/16 bit for finish cut
- Toolbit -- 1/8 bit for Roughcut

With the milling completed, i kept the pieces from the milling operation for recycle purpose

A table was prepared for the casting process so as to avoid messing up the place. Also Safety wears was used for protection

With that done, next i mixed the silicon Mold Star™ rubbers part A and B together in a mixure of ratio 1A:1B in a cup and stir till its well mixed

Then i cut acrylic material and place at the edges of the mold and then poured the mixure in it. i waited for 25 minute for it to dry

having casted our first part with silicon. I used this as a negative mold for my final cast which is ceramic, I made a stand to keep it in place before i could pour the ceramic mixture in it. i also added baby powder in the mold with the help of a brush.
I used The Smooth-Cast™ 300 Series of liquid plastics that are ultra-low viscosity casting resins that yield castings that are bright white and virtually bubble free.